Gti6 Engine, Mi16 Box + 309 Drive Shafts

[matty_gti 20]

Finally got around to fitting the shafts today but the passenger side really wasn't playing ball.

 

I've got a GTI6 engine with a MI16/S16 box + 309 shafts. The drivers side shaft seems to be ok but the pass side won't just wont fully slide home. Having a look at the box and doing some measuring, if you look at the pic below...

 

 

The distance from the cylindrical shaft inside (arrowed) to the metal seat (arrowed) is approx 64mm however in this pic...

 

 

The distance between the two yellow ends is approx 70mm.

 

I then tried the 1.9 8v box I have in the garage and the 309 pass side shaft slides all the way home as the metal shaft in that to the metal sleeve is 7.1 so that's hunky dory.

 

Anyone shed any light on this???.

 

Cheers.

[Anthony 1,002]

Later BE gearboxes have a diff that's causes the driveshaft issue that you've come across - swap the diff over with the one from your 1.9 box and it'll be fine (obviously swap the crownwheel over as that's matched to the gearbox). Not sure about S16 'boxes, but certainly VTS ones are like this.

[Miles 331 1 Cars]

Yes S16 and phase 2 405's with the old ZX16v for WP use the revised diff with the different offset for the N/S shaft,

As said it's best to swap diff's as in the long term it will save allot of hassle, I;ve been stung by this a couple of time with conversions from other companies up North so it made swapping a shaft a pain as I had to use the old Inner cup to get them going again, but you never end up with a 100% shaft this way.

[matty_gti 20]

Cheers for help guys, looks like I will be changing the diff then!. So I would keep the MI16 crown wheel on the 1.9 diff?. And it's only the pass side offset that's effected?.

What did you mean by this miles?

I had to use the old Inner cup to get them going again, but you never end up with a 100% shaft this way.

As if there is any way round chaning the diff's that would be great as I really don't want to take the engine and box out again!.

Could I even modify the shaft as in cut it down by 7mm (the difference in offsets) and then grind/extend the splines by 7mm to make it fit properly?.

 

Cheers.

Edited May 2, 2011 by matty_gti

[Masekwm 2]

The alternative to changing the diff is to change the inner (gearbox) side of the driveshaft to the one that is meant to be used, so you could split the shaft and fit the xsara inner part.

[Miles 331 1 Cars]

I have seen the cut of method used by a well known company with '1' in it, I was quite shocked when I saw it as it was just cut down and the end ground down as you will never extend the spline's and it gets back to the situation I had if anyone else was to change a shaft.

Or the 306, 405, 406 inner Cup joint can be used but is only getting around the problem and not fixing it

[Anthony 1,002]

As if there is any way round chaning the diff's that would be great as I really don't want to take the engine and box out again!.

You can swap the diff over with the engine and box fitted in the car - you'll need to tilt the engine forward a bit or drop the subframe, but it is doable.

 

And yes, you need to transfer the crownwheel from the S16 diff over to the 1.9 diff.

[matty_gti 20]

Thanks for the help guys.

 

Considering how much money the car has soaked up and how long it's taken I think I'm going to swap over the inner cup of the shaft for now and when the car is MOT'd etc then I will splash out on a LSD .

 

Will the inner cup from a 306 GTI6 be ok?, and regarding the drivers side shaft that is all ok for the box as it is?.

 

Cheers.

[Henry Yorke 269 3 Cars]

I had exactly this problem with an S16 gearbox in my CTI. After bolting it all together it is not the sort of thing you want to discover :'( The diff was swapped over in the end.

 

Is there any specific reason that the design is different? Is it meant to be stronger?

[matty_gti 20]

After bolting it all together it is not the sort of thing you want to discover :'(

 

No it's not, I thought 'great I'm making progress today' then the words 'o crap' were grumbled!

 

I'm guessing the diff's were just a re-deisgn or designed to be used with more powerful engines such as the S16, Mi16 and GTI6 etc.

 

It is just the pass side that has the problem fitting so the D.side does not need changing at all?, and just to confirm an inner cup from a GTI6 shaft will fit?.

 

Thanks.

Edited May 4, 2011 by matty_gti

[ricey205gti 0]

Did you get this sorted in the end as i have the same problem

Cheers

[allye 530 3 Cars]

Proper thread resurrection!

 

If you read the thread it will solve your issue.

[jackherer 543]

I will splash out on a LSD .

^^^That is the best solution